System of Collapsible Panels and Structures

ABSTRACT

A panel has a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form the panel when the frame member is in the unfolded orientation. A collar is attached to the panel along an edge of the panel, with the collar extending radially away from the periphery of the panel, and a magnet piece is secured inside the collar.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to collapsible panels and structures, and in particular, to collapsible panels and structures which can be connected by a system of magnetic connectors.

2. Description of the Prior Art

There are presently many collapsible structures that are being provided for use by children and adults in a number of different applications. Examples of these collapsible structures are illustrated in the following patents: U.S. Pat. No. 5,816,954 (Zheng), U.S. Pat. No. 6,006,772 (Zheng), U.S. Pat. No. 5,778,915 (Zheng), U.S. Pat. No. 5,467,794 (Zheng), U.S. Pat. No. 5,975,101 (Zheng), U.S. Pat. No. 5,722,446 (Zheng), U.S. Pat. No. 4,858,634 (McLeese), U.S. Pat. No. 4,825,592 (Norman), U.S. Pat. No. 5,964,533 (Ziglar), U.S. Pat. No. 5,971,188 (Kellogg et al.), U.S. Pat. No. 6,485,344 (Arias), U.S. Pat. No. 6,343,391 (LeGette), U.S. Pub. No. 2004/0139997 (Zheng) and U.S. Pat. No. 5,038,812 (Norman), among others These collapsible structures are supported by one or more frame members that can be twisted and folded to reduce the overall size of the structure. These collapsible structures can be used in a wide variety of applications, such as containers, tents, play structures, executive toys, shelters, sports structures, and others. As a result, collapsible structures have become very popular.

Most of these previous collapsible structures are preformed into specific configurations of panels that are stitched together. As such, they can only be used in their preformed configurations and the play variety often wanes over time. Attempts were made to provide separate panels that can be removably or adjustably attached to other panels or structures. For example, U.S. Pat. No. 6,220,265 to Zheng discloses the use of opposite VELCRO™ pads and other fabric connectors to connect panels. However, while the fabric connectors allow for the panels to be 3C adjusted or replaced, the variations available to the user are still rather limited. In addition, VELCRO™ pads are also rather limiting in use because two opposing (male and female) pads are needed, and these pads need to be secured to specific locations on different panels. As a result, the user is still limited in that he or she can only effectuate a connection at specific pre-set locations along different panels.

SUMMARY OF THE DISCLOSURE

It is an object of the present invention to provide a system of collapsible panels and structures that can be conveniently assembled and disassembled at a variety of locations at the discretion of the user.

In order to accomplish the objects of the present invention, a collapsible structure is provided with a plurality of panels, the plurality of panels including at least a first panel and a second panel, each panel having a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of each respective frame member to form the panel for each frame member when the frame member is in the unfolded orientation, each panel having a left side and a right side, with the left side of one panel hingedly coupled to the right side of an adjacent panel. A magnetic connector connects a separate item to a portion of the frame member of one of the panels.

In another embodiment, a magnetic connector is permanently secured to a portion of the fabric material at a location offset from the frame member, with a separate item having a portion thereof that is made of metal, and being removably attached to the magnetic connector at the location of metal portion.

In yet another embodiment, two or more magnetic connectors can connect two or more panels together at the fabric portion of these panels.

In yet another embodiment, a panel comprises a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form the panel when the frame member is in the unfolded orientation. A collar is attached to the panel along an edge of the panel, with the collar extending radially away from the periphery of the panel, and a magnet piece is secured inside the collar.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a system of collapsible panels and structures according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view of the section 2-2 in FIG. 1.

FIG. 3 is a partial cut-away view of the section A of the panel of FIG. 1 illustrating a frame member retained within a sleeve, and a magnet secured to the fabric adjacent the sleeve.

FIG. 4 is a partial cut-away view of the section A of the panel of FIG. 1 illustrating a frame member retained within a sleeve, and a magnet secured as part of the sleeve.

FIG. 5 is a partial cut-away view of the section B of the panel of FIG. 1 illustrating a magnet secured to the fabric.

FIGS. 6A through 6D illustrate how the collapsible structure of FIG. 1 may be twisted and folded for compact storage.

FIG. 7 illustrates another system of collapsible panels and structures according to the present invention.

FIGS. 8A and 8B illustrate how three panels can be connected by two magnetic connectors.

FIGS. 9 and 10 illustrate the use of stabilizing members to support the structures of the present invention.

FIG. 11 is a cut-away exploded view of a collar and magnet system according to an embodiment of the present invention.

FIG. 12 illustrates a modification made to the collar and magnet system of FIG. 11.

FIG. 13 illustrates yet another modification made to the collar and magnet system of FIG. 11.

FIGS. 14-16 illustrate how the collar and magnet system of FIGS. 11-13 can be used in connection with panels to form a variety of play objects.

FIG. 17 illustrates another embodiment of the present invention where magnetic pieces are provided on the fabric material of panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.

As shown in FIGS. 1-6, a structure 20 is provided that comprises four panels 22, 24, 26 and 28 connected to each other to encircle an enclosed space. Each panel 22, 24, 26, 28 can have four sides, such as a left side 30, a bottom side 32, a right side 34 and a top side 36, although each panel 22, 24, 26, 28 can assume any configuration and have any number of sides. Each panel 22, 24, 26 and 28 has a frame retaining sleeve 38 provided along and traversing the four edges of its four sides 22, 24, 26, 28. A frame member 40 is retained or held within each respective frame retaining sleeve 38 to support each panel 22, 24, 26, 28. Only the frame member 40 is shown in FIGS. 3 and 4; the other frame members are not shown but are the same as frame member 40.

The frame members 40 may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The frame members 40 are preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame members should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each frame member 40 is capable of assuming two positions or orientations, an open or expanded position such as shown in FIG. 1, or a folded position in which the frame member is collapsed into a size which is much smaller than its open position (see FIG. 6D).

Fabric or sheet material 42 extends across each respective panel 22, 24, 26, 28, and is held taut by the respective frame member 40 when in its open position. The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric should be water-resistant and durable to withstand the wear and tear associated with rough treatment. The frame members 40 may be merely retained within the respective frame retaining sleeves 38 without being connected thereto. Alternatively, the frame retaining sleeves 38 may be mechanically fastened, stitched, fused, or glued to the respective frame members 40 respectively, to retain them in position.

FIG. 2 illustrates one possible connection for connecting adjacent edges of two panels 22 and 24. The fabric pieces 42 are stitched at their edges by a stitching 44 to the respective sleeves 38. Each sleeve 38 may be formed by folding a piece of fabric. The stitching 44 also acts as a hinge for the panels 22 and 24 to be folded upon each other, as explained below. The connections for the three other pairs of adjacent edges may be identical. Thus, the connections on the left side 30 and the right side 34 of each panel 22, 24, 26, 28 act as hinge connections for connecting an adjacent panel.

At the top side 36 and the bottom side 32 of each panel 22, 24, 26, 28, where there is no hinge connection to an adjacent panel, the frame retaining sleeve 38 may be formed by merely folding over the corresponding fabric piece and applying a stitching 46 (see FIGS. 3 and 4). The fabric piece 42 for the corresponding panel may then be stitched to the sleeve 38.

While the structure 20 of FIG. 1 is shown and described as having four panels, each having four sides, it will be appreciated that the structure 20 may be made of any number of panels, each having any number of sides, without departing from the spirit and scope of the present invention. For example, each structure may have at least one panel, and each panel may have three or more sides. Thus, the structures of the present invention may take a variety of external shapes. However, each panel, regardless of its shape, is supported by at least one frame member 40.

FIGS. 6A through 6C describe the various steps for folding and collapsing the structure 20 of FIG. 1 for storage. The first step consists of pushing panels 22 and 24 towards panels 28 and 26, respectively, about their hinged connections so that panel 22 collapses upon panel 28 and panel 24 collapses upon panel 26. Then, the two panels 22 and 28 are folded so as to be collapsed upon the two panels 24 and 26 to form a stack of four panels. In the second step, the structure 20 is then twisted and folded to collapse the frame members 40 and panels 22, 24, 26, 28 into a smaller shape. In particular, the opposite border 60 of the stack of panels 22, 24, 26, 28 is folded in (see arrow 62 in FIG. 6A) upon the previous fold to further collapse the frame members 40 with the panels. As shown in FIGS. 6B and 6C, the folding is continued so that the initial size of the structure 20 is reduced until the frame members 40 and panels are collapsed on each other (see FIG. 6D) to provide for a small essentially compact configuration having a plurality of concentric frame members 40 and layers of the panels 22, 24, 26, 28 so that the collapsed structure 20 has a size which is a fraction of the size of the initial structure.

The present invention provides magnetic connectors that allow a number of other items to be removably connected to the structure 20. For example, as shown in FIG. 1, other panels 48 and 50 (which can be identical in construction to the any of the panels 22, 24, 26, 28) can be removably coupled to any panel 22, 24, 26, 28 via magnetic connectors 52. Similarly, another structure 54 (which can be identical in construction to the structure 20 but smaller in size) can also be removably coupled to any panel 22, 24, 26, 28 via magnetic connectors 52.

The magnetic connectors 52 are illustrated in greater detail in FIGS. 2-5. The present invention provides many ways to embody the magnetic connectors 52.

In one embodiment, each magnetic connector 52 can be comprised of a piece of magnet 58 encased inside a fabric pouch 56 (see FIG. 1). This connector 52 can be used in a simple manner, by placing it on an edge of the panel 28 and then aligning an edge of the other panel 50 to the connector 52. Since the frame members 40 in the panels 28 and 50 are made of metal, they will experience a strong attraction to the connector 52 and therefore the two panels 28 and 50 will be coupled at the location of the connector 52. By providing multiple connectors 52, as shown in FIG. 1 along the same edges of the panels 28 and 50, and positioning these connectors 52 between the frame members 40 of two panels (e.g., 28 and 50), a very strong connection can be created between the two panels 28, 50. This type of connector 52 will also allow the user to connect any metallic item to an edge of any of the panels 22, 24, 26, 28, and 50. This is also shown in FIG. 7 with the panels 80 and 50.

In another embodiment, magnetic connectors 521 are comprised of a piece of magnet 58 encased inside a compartment formed by the underlying fabric 42 of a panel and a covering piece of fabric 62. See FIG. 5. These connectors 521 are positioned at fixed locations on the panels, and can be used to connect any metallic item to the fabric 42 of the panel at the location of the connectors 521.

In yet another embodiment, a magnetic connector 522 can be secured to the fabric 42 adjacent the sleeve 38. See FIG. 3. The magnetic connectors 522 are comprised of a piece of magnet 58 encased inside a compartment formed by the underlying fabric 42 of a panel and a covering piece of fabric 62, and positioned adjacent the sleeve 38. These connectors 522 are positioned at fixed locations on the panels, and can be used to connect any metallic item to the fabric 42 of the panel at locations along the edge of the panel.

In yet a further embodiment, the magnetic connectors can comprise a piece of magnet 58 secured inside a sleeve 38, as best shown in FIG. 4. The magnet 58 can be secured to a location on the inner wall of the sleeve 38 by glue, or simply through its automatic attraction/connection force with the metallic frame member 40. These magnetic connectors can be used to connect any metallic item to the frame member 40 of the sleeve 38 that it is retained inside.

The magnetic connectors according to the present invention provide a wide variety of options for removably connecting collapsible panels, collapsible structures and other metallic items, thereby providing the consumer with enhanced play variety and enjoyment. FIGS. 1 and 7 illustrate a few examples of these play options.

Referring to FIG. 1, the panel 50 can be coupled to the top of the structure 20 so that the panel 50 can function as a roof. This can be accomplished by using separate connectors 52 to connect the edges of the panel 50 with the top edges 36 of the panels 22, 24, 26, 28. In addition, the panel 48 can be removably coupled to the fabric 42 of panel 26; specifically, magnetic connectors 521 can be stitched to the fabric 42 and they could directly attract (connect) the metallic frame member 40 of the panel 48. Similarly, the structure 54 can be removably coupled to the panel 24 via two sets of magnetic connectors 52 in accordance with the technique shown in FIGS. 8A and 8B, or through magnetic connectors 521 that are stitched to the fabric 42 of the panel 24.

Referring to FIG. 7, the structure 20 can be embellished by adding a fabric roof 70. The roof 70 (which does not have an encircling frame member 40) can be a piece of fabric with magnetic connectors 521 encased along opposite edges 72, 74 of the roof 70, so that these opposite edges 72, 74 can be coupled to the top edges 36 of the panels 22 and 26. In addition, another fabric roof 70 can be used to create a covered area defined by a single panel (e.g., 50 from FIG. 1) and the panel 24 by coupling the opposite edges 72, 74 to the top edges 36 of the panels 24 and 50. Instead of encased connectors 521, it is also possible to use separate connectors 52, and place them on top of the fabric roofs 70 so that each edge 72, 74 of the fabric roofs is sandwiched between a connector 52 and the underlying frame member 40 on the structure 20. Thus, when FIGS. 1 and 7 are compared, it can be seen that the magnetic connectors 52 or 521 allow the panel 50 to be used for different purposes to vary and enhance the play options for the system of panels 50 and structures 20 shown in FIG. 1.

In addition, triangular panels 80 can be provided as part of the system and used in different ways. For example, as shown in FIG. 7, one triangular panel 80 can be coupled to the fabric 42 of the panel 22 simply by using two magnetic connectors 52 to sandwich the fabric of the triangular panel 80 to the fabric 42 of the panel 22. Here, this illustrates how two magnetic connectors 52 can be effectively used to easily couple two fabric pieces together. FIGS. 8A and 8B illustrate this in greater detail, where FIGS. 8A and 8B show three panels PA, PB and PC (which can be identical in construction to panels 22, 24, 26, 28, 50) connected by two magnetic connectors M (which can be identical to 52) by sandwiching them between the connectors M.

In addition, another magnetic connector 52 can be used to couple the fabric of a triangular panel 80 to a side of the frame member 42 of the panel 50 in a manner where the panel 80 is perpendicular to the panel 50. Here, the magnetic connector 52 is used to connect to the metallic frame member of the panel 50, with the fabric of the panel 80 sandwiched in between. Another triangular panel 80 can be coupled to the opposite side edge of the panel 50. Thus, the panels 80 can be used as base supports for holding the panel 50 vertically upright.

The present invention provides a unique connection system for use with collapsible panels and structures because it relies on the metallic characteristic of the frame members 40 to couple other panels and items. Specifically, the metallic frame members 40 would attract to magnets, so the present invention uses the magnetic forces to create connection points. This provides a much more flexible system of connectors when compared with other known connectors (e.g., VELCRO™ pads, fabric connectors, etc.), and is more convenient and easy to use.

Since the collapsible structures 20 and panels of the present invention are often used to support other panels, structures and items, stability can become compromised. Therefore, stabilizing members can be provided to help maintain the stability of the resulting structure. Referring now to FIG. 9, the structure 20 can be provided with a stabilizing assembly 100 which includes fabric extensions 102, 104 and a supporting bar-and-cord frame 106. Specifically, fabric extensions 102, 104 extend on either side of a panel (e.g., 22), and each extension 102, 104 has a curved or arc shape. Spaced-apart sleeve portions 108 are provided along the top of the extensions 102, 104, and along the top edge 36 of the panel 22, so that the sleeve portions 108 together define a semi-circular shape. The bar-and-cord frame 106 is comprised of a plurality of bar pieces 112 separated by cords 114. The bar pieces 112 have opposing ends that are adapted to be tight-fitted to the ends of adjacent bar pieces 112 so that the bar-and-cord frame 106 defines a semi-circular shape when completely assembled for deployment. The assembled bar-and-cord frame 106 can be inserted through the sleeve portions 108 so that the bar-and-cord frame 106 can function as a stabilizing member to the side of the structure defined by the panel 22.

FIG. 10 illustrates a different type of bar-and-cord frame where two such frames 120 are deployed on the fabric 42 of the panel 22 in a crossing or “+” shaped configuration, as defined by sleeve portions 124 positioned on the fabric 42 to define the configuration.

FIG. 10 also illustrates another type of stabilizing member, which can take the form of another panel 140. Specifically, magnetic connectors 521 can be sewn onto specific locations of the fabric 42 of the panel 26 and the floor fabric 132, and then the panel 140 can be coupled to the panel 28 and the floor 142 by placing the edges of the panel 140 against these connectors 521 so that the edges of the metallic frame member 40 inside the panel 140 can be coupled to the connectors 521. As a result, the panel 140 can function as a stabilizing member by being positioned in an angled manner to hold the panel 26 upright against the floor 142.

As yet another example, as shown in FIG. 7, the triangular panels 80 can be used as stabilizing members for a single panel 50.

The principles of the present invention also allow a variety of other items to be removably coupled to a collapsible structure or panel even without the use of the magnetic connectors 52, 521 or 522. Specifically, the metallic nature of the frame members 40 allow for any object having a magnet incorporated therein to be coupled to the frame members 40.

For example, referring to FIG. 9, a base plate 130 defines a planar upper surface that has a plurality of studs 132 provided thereon. Magnet pieces 134 can be housed inside the base plate 130. The base plates 130 can be used to removably couple play objects 136 that are supported on a base 138. The base 138 is adapted to be coupled to the studs 132 on the support base plates 130 in a manner that is similar to a LEGO™ connection. Specifically, most LEGO™ brick pieces have two basic components: studs on top and tubes on the inside. A brick's studs are slightly bigger than the space between the tubes and the walls. When the bricks are pressed together, the studs push the walls out and the tubes in. The material is resilient and wants to hold its original shape, so the walls and tubes press back against the studs. Friction also plays a role, preventing the two bricks from sliding apart. This stud-and-tube coupling system uses an interference fit, which provides a firm, friction-based connection between two parts without the use of an additional fastener. Thus, the bottom of the base 138 would also include the tubes and walls that are normally found at the base of a conventional LEGO™ brick.

Therefore, in FIG. 9, the base plate 130 itself has a magnet 134 that allows it to be removably coupled to the frame member 40 of any of the panels 22, 24, 26, 28.

FIG. 11 illustrates another embodiment of the present invention where the magnet piece(s) are retained in a separate sleeve or collar that surrounds the sleeve 38 which retains the frame members 40. In FIG. 11, a single magnet piece 1002 is retained inside a collar or sleeve 1004. The collar 1004 is large enough to also encapsulate the portion of the underlying frame member 40 and sleeve 38 to which the collar 1004 is stitched. The collar 1004 is also stitched to the fabric piece 42 of the specific panel. The magnet piece 1002 can be secured inside the collar 1004 by glue, or by providing the magnet piece 1002 inside a pouch (not shown) that is sewn to the inside of the collar 1004. The collar 1004 extends radially away from the periphery of the panel defined by the frame member 40, and the magnet piece 1002 is also positioned radially away from the periphery of the panel by a certain distance, such as at least one inch, and preferably more than one inch as best shown in FIGS. 12-13 below.

FIG. 12 illustrates a modification to the embodiment of FIG. 11 where a plurality (three) of magnet pieces 1002 are provided inside the collar 1004. The magnet pieces 1002 can be spaced apart by any desired distance, or arrangement.

FIG. 13 illustrates yet another modification to the embodiment of FIG. 11 where a plurality (two) of magnet pieces 1002 are provided inside the collar 1004, and a separate collar 1006 is sewn to the outer surface of the collar 1004 and extending radially away from the collar 1004. The separate collar 1006 retains one or more magnetic pieces 1002.

The separate collars 1004, 1006 in FIGS. 11-13 serve an important purpose in providing a more flexible connector. In the other embodiments shown and described herein, the magnetic connectors are affixed to or adjacent an edge of the panel, and there is not a lot of adjustability in terms of where the connections must take place. However, the collars 1004, 1006 extend away from the periphery of the panels by a certain distance, and can be provided at varying lengths, so that the magnet pieces 1002 housed inside these collars 1004 and 1006 can extend greater distances away from the edge or periphery of the panel for providing a greater variety of connections.

FIGS. 14-17 illustrate a few examples of the versatility of connections provided by the collars 1004 and their magnet pieces 1002. For example, FIG. 14 illustrate how four separate collars 1004 stitched to four separate sides of a panel 1012 can be used to removably couple two other panels 1014 and 1016, where separate magnet pieces 1002 in the collars 1004 couple the metal frame member 40 of the respective panels 1014 and 1016. In this embodiment, the panels 1014 and 1016 can be generic panels that do not have any magnetic connectors associated therewith, so that the panel 1012 with the magnetic connecting collars 1004 can actually be used in conjunction with other generic panels to construct or assemble different configurations of structures.

FIG. 15 illustrates another example where a panel 1020 has two collars 1004 along one side edge that has two magnetic pieces 1002 inside each collar 1004, and where the two magnet pieces 1002 are used to removable couple the metal frame members 40 of two other panels 1022 and 1024. The panel 1020 has two other collars 1004 along an opposite side edge that has one magnet piece 1002 in each collar 1004, and where each magnet piece 1002 is used couple to a magnetic connector 52 in a manner where another panel 1026 is positioned between the collar 1004 and the magnetic connector 52, thereby allowing another generic panel (such as 1026) to be removably coupled to a collar 1004 that extends from the panel 1020.

FIG. 16 illustrates another example where a panel 1040 has collars 1004 extending from side edges thereof. Separate play objects 1042 that have a magnet piece connected or mounted thereto can be removably coupled to the magnet pieces 1002 on these collars 1004. The play objects 1042 can be an animal, an alphabet character, or a number, among other things. In addition, another generic panel 1044 can also removably coupled to one of the collars 1004 by a magnetic connector 52.

FIG. 17 illustrates a play structure 1100 that is comprised of four separate panels 1102. In addition, a panel 1104 is provided with magnetic pieces 1106 provided on the fabric material 1108 of the panel 1104. In particular, the magnetic pieces 1106 can be sewn into a pouch that is then stitched to the fabric material 1108. The magnetic pieces 1106 can be used to removably couple the panel 1104 to the frame members of any of the panels 1102 of the structure 1100. This allows a basic structure 1100 to be modified and enhanced by removably coupling other panels (e.g., 1104) at any desired location along the frame members of any of the panels 1102.

While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. 

What is claimed is:
 1. A panel comprising a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form the panel when the frame member is in the unfolded orientation, wherein the frame member defines the periphery of the panel in the unfolded orientation, and the panel has at least one edge; a collar attached to the panel along the at least one edge, the collar extending radially away from the periphery of the panel; and a magnet piece that is secured inside the collar.
 2. The panel of claim 1, wherein each panel has a sleeve that retains the respective frame member for the panel, with the sleeve being separate from the collar.
 3. The panel of claim 1, wherein the magnet piece is a first magnet piece, and wherein the collar includes at least a second magnet piece.
 4. The panel of claim 1, wherein the collar is a first collar, and further including a second collar separate from the first collar, with the second collar sewn to an outer surface of the first collar and extending radially away from the first collar, and wherein the second collar includes at least one magnet piece.
 5. The panel of claim 3, wherein the first and second magnet pieces are spaced apart from each other.
 6. The panel of claim 1, further including a play object having a magnet associated therewith, and with the play object removably coupled to the magnet piece in the collar. 